Cyclone module for vacuum cleaner

ABSTRACT

A cyclone module for a vacuum cleaner includes a primary separator, a bulk collection chamber, at least one secondary separator and a fines collection chamber. First and second doors are provided for closing debris outlets at the bottom ends of the bulk and fines collection chambers, respectively. The fines collection chamber is elevated within the bulk collection chamber, with the second door spaced above the first door.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. application Ser. No.15/363,645, filed Nov. 29, 2016, now U.S. Pat. No. 10,231,587, whichclaims the benefit of U.S. Provisional Patent Application No.62/263,132, filed Dec. 4, 2015, which is incorporated herein byreference in its entirety.

BACKGROUND

Upright vacuum cleaners employ a variety of dirt separators to removedirt and debris from a working air stream. Some dirt separators use oneor more frusto-conical-shaped separator(s) and others use high-speedrotational motion of the air/dirt to separate the dirt by centrifugalforce. Typically, working air enters and exits at an upper portion ofthe dirt separator as the bottom portion of the dirt separator is usedto collect debris. Before exiting the dirt separator, the working airmay flow through an exhaust grill. The exhaust grill can haveperforations, holes, vanes, or louvers defining openings through whichair may pass.

A dirt collector can be provided for collecting the removed dirt fromthe working air stream, and can be separate or integral with the dirtseparator. In vacuum cleaners where the dirt separator and collector areintegral, the entire separator/collector assembly can be removable fromthe vacuum cleaner for emptying collected dirt. In some cases, a bottomwall of the dirt collector serves as a dirt door, and is provided with arelease mechanism for opening the dirt door to empty the accumulatedcontents.

Some cyclonic dirt separators have two separation stages, and use a dirtcollector with individual chambers for receiving dirt separated at eachstage. In one design, dirt from the second or downstream separationstage is collected within a centrally-located tube that meets the bottomwall of the dirt collector that serves as the dirt door.

BRIEF DESCRIPTION

An aspect of the disclosure relates to a cyclone module for a vacuumcleaner, including a module housing defining a longitudinal axis of themodule, a primary separator comprising a cyclone chamber, a bulkcollection chamber having a bottom end defining a first debris outlet,at least one secondary separator fluidly downstream from the primaryseparator; a first door coupled with the module housing and closing thefirst debris outlet, a fines collection chamber having a bottom enddefining a second debris outlet wherein the bottom end of the finescollection chamber is above the bottom end of the bulk collectionchamber, with the second debris outlet spaced above the first door alongthe longitudinal axis of the module, and a support member have a firstend operably coupled to the first door and a second end defining asecond door configured to close the second debris outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a vacuum cleaner that can be providedwith a cyclone module according to an aspect of the present disclosure.

FIG. 2 is a sectional view of a cyclone module for a vacuum cleaner.

FIG. 3 is a sectional view of the cyclone module from FIG. 2, with adirt door in an open position.

FIG. 4 is a perspective view of the dirt door of the cyclone module fromFIG. 2.

FIG. 5 is a perspective sectional view of another cyclone module for avacuum cleaner.

FIG. 6 is an exploded view of the cyclone module from FIG. 5.

FIG. 7 is a perspective view of another cyclone module for a vacuumcleaner.

FIG. 8 is a perspective view of the cyclone module from FIG. 7, with adirt door in an open position.

FIG. 9 is a sectional view of another cyclone module for a vacuumcleaner.

FIG. 10 is a sectional view of yet another cyclone module for a vacuumcleaner.

FIG. 11 is a sectional view of another cyclone module for a vacuumcleaner.

DETAILED DESCRIPTION

Aspects of the present disclosure relate to a cyclone module for avacuum cleaner, which may be in the form of an upright vacuum cleaner, ahand-held vacuum cleaning device, or as an apparatus having a floornozzle or a hand-held accessory tool connected to a canister or otherportable device by a vacuum hose or conduit. Additionally, in someaspects of the present disclosure the vacuum cleaner can have fluiddelivery capability, including applying liquid or steam to the surfaceto be cleaned, and/or fluid extraction capability. As used herein, theterms “dirt” and “debris” are used interchangeably, and encompass dirt,dust, soil, hair, and other debris.

One aspect of the present disclosure of the cyclone module has anelevated fines catcher and a dirt door that empties the primary andsecondary dirt collection chambers simultaneously. Other aspects of thepresent disclosure of the cyclone module include a combination of theelevated fines collector feature with simultaneous debris chamberemptying, hair/debris management features and/or improved filtration.

In yet another aspect of the present disclosure, the cyclone module caninclude an elevated fines catcher with a fines door, independent of theprimary dirt door and configured to automatically close when the cyclonemodule is under vacuum and automatically open when vacuum inside thecyclone module ceases, i.e. when a working air flow through the cyclonemodule stops.

In additional aspects of the present disclosure, the cyclone module canhave individual dirt doors associated with each of the primary andsecondary dirt collection chambers respectively. The primary door andfines catcher door can be actuated simultaneously or independently.

The elevated fines catcher provides more space for debris collection inthe primary collection chamber. Also, the swirling airflow within thecyclone module tends to agglomerate dust and hair into a ball at thecenter of the tank. Previous designs with centrally located finescollector tube extend the fines collector tube all the way to the bottomof the tank, which often includes a bottom-empty door. Thus, eliminatinga traditional fines collector tube that typically occupies the center ofthe tank, allows the swirling airflow to ball-up the dust and hair moreeffectively. An unobstructed bottom tank has less turbulence. This alsoallows for a centrally located fines separator that empties as the firstcollection chamber empties.

As used herein, the term “separator” or “dirt separator” or “debrisseparator” is inclusive of cyclones or cyclonic separators, separatorscreens having a mesh material, and grills, including grills having aperforated or louvered side wall.

One example of a suitable vacuum cleaner in which the various aspects ofthe present disclosure of the cyclone module disclosed herein can beused is disclosed in U.S. Patent Application Publication No.2015/0289738, published Oct. 15, 2015, now U.S. Pat. No. 9,693,664,which is incorporated herein by reference in its entirety and shown inFIG. 1.

Referring to FIG. 1, the upright vacuum cleaner 10 comprises an uprighthandle assembly 12 pivotally mounted to a foot assembly 14. For purposesof description related to the figures, the terms “upper,” “lower,”“right,” “left,” “rear,” “front,” “vertical,” “horizontal,” andderivatives thereof shall relate to the illustration as oriented in FIG.1 from the perspective of a user behind the vacuum cleaner, whichdefines the rear of the vacuum cleaner. However, it is to be understoodthat aspects of the present disclosure may assume various alternativeorientations, except where expressly specified to the contrary.

The handle assembly 12 further comprises a primary support section 16with a grip 18 on one end to facilitate movement by a user. A motorcavity 20 is formed at an opposite end of the handle assembly 12 tocontain a conventional suction source such as a vacuum fan/motorassembly 21 oriented transversely therein and which is configured togenerate a working airstream through a working air path of the vacuumcleaner that extends from a “dirty” air inlet to a “clean” air outlet.The vacuum fan/motor assembly can form a portion of the working airpath. The handle assembly 12 pivots relative to the foot assembly 14through a pivot axis that is coaxial with a motor shaft (not shown)associated with the vacuum fan/motor assembly 21. A post-motor filterhousing 22 is formed above the motor cavity 20 and is in fluidcommunication with the vacuum fan/motor assembly 21, and receives afilter media (not shown) for filtering air exhausted from the vacuumfan/motor assembly 21 before the air exits the vacuum cleaner 10 throughthe air outlet. A mounting section 24 on the primary support section 16of the handle assembly 12 receives a cyclone module 26 for separatingdirt and other contaminants from the working airstream, and can form aportion of the working air path. The cyclone module 26 can be anycyclone module described herein.

The foot assembly 14 comprises a housing 28 with a suction nozzle 30formed at a lower surface thereof and that is in fluid communicationwith the vacuum fan/motor assembly 21. The suction nozzle 30 defines theair inlet of the working air path. While not shown in FIG. 1, anagitator can be positioned within the housing 28 adjacent the suctionnozzle 30 and operably connected to a dedicated agitator motor, or tothe vacuum fan/motor assembly 21 within the motor cavity 20 via astretch belt. Rear wheels 32 are secured to a rearward portion of thefoot assembly 14 and front wheels (not shown) are secured to a forwardportion of the foot assembly 14 for moving the foot assembly 14 over asurface to be cleaned. When the cyclone module 26 is received in themounting section 24, as shown in FIG. 1, the cyclone module 26 is influid communication with, and fluidly positioned between, the suctionnozzle 30 and the vacuum fan/motor assembly 21 within the motor cavity20. At least a portion of the working air path between the suctionnozzle 30 and the cyclone module 26 can be formed by a vacuum hose 34that can be selectively disconnected from fluid communication with thesuction nozzle 30 for above-the-floor cleaning.

FIGS. 2-3 are sectional views of a cyclone module 36 for a vacuumcleaner. The cyclone module 36 can be used as the cyclone module 26 ofthe vacuum cleaner 10 shown in the FIG. 1, or for another vacuumcleaner. The cyclone module 36 comprises a housing 38 at least partiallydefining a two-stage cyclone separator including a first stage definedby a first cyclone chamber 40 for separating contaminants from adirt-containing working airstream and an associated first or bulk dirtcollection chamber 42 which receives contaminants separated by the firstcyclone chamber 40, and a second stage defined by a second cyclonechamber 44 for separating contaminants from the working airstreamreceived from the first stage and an associated second or fines dirtcollection chamber 46 which receives contaminants separated by thesecond cyclone chamber 44. One or both of the cyclonic stages can becentered on a central axis X of the cyclone module 36, which can extendlongitudinally through the housing 38. Further, the first and secondstages can be concentric, with the second stage positioned within thefirst stage and both centered on the central axis X. It is noted thatwhile a two-stage cyclone separator is illustrated herein, it is alsocontemplated that the cyclone module 36 can be configured withadditional separation stages or one separation stage.

The module housing 38 is common to the first cyclone chamber 40 and thebulk collection chamber 42, and includes a side wall 48, a bottom wall50, and a cover 52. The side wall 48 is illustrated herein as beinggenerally cylindrical in shape, with a diameter that increases in adirection toward the bottom wall 50. The side wall 48 includes a loweror bottom edge 53 that defines a debris outlet for the bulk collectionchamber 42. The bottom wall 50 in the illustrated example comprises adirt door that can be selectively opened, such as to simultaneouslyempty the contents of the collection chambers 42, 46.

The dirt door 50 is pivotally mounted to the side wall 48 by a hinge 54.A door latch 56 is provided on the side wall 48, opposite the hinge 54,and can be actuated by a user to selectively release the dirt door 50from engagement with the bottom edge of the side wall 48. The door latch56 is illustrated herein as comprising a latch that is pivotally mountedto the side wall 48 and spring-biased toward a closed position shown inFIG. 2. By pressing the upper end of the door latch 56 toward the sidewall 48, the lower end of the door latch 56 pivots away from the sidewall 48 and releases the dirt door 50, under the force of gravity, to anopen position shown in FIG. 3, allowing accumulated dirt to be emptiedfrom the collection chambers 42, 46 through the open bottom of themodule housing 38. A gasket 58 can be provided between the dirt door 50and the bottom edge of the side wall 48 to seal the interfacetherebetween when the dirt door 50 is closed.

An air inlet to the cyclone module 36 can be at least partially definedby an inlet conduit 60. An air outlet from the cyclone module 36 can beat least partially defined by an outlet conduit 62 extending from thecover 52. The inlet conduit 60 is in fluid communication with thesuction nozzle 30 (FIG. 1) and the outlet conduit 62 is in fluidcommunication with the vacuum fan/motor assembly 21 within the motorcavity 20 (FIG. 1).

The cyclone module 36 further includes a grill 64 for guiding workingair from the first cyclone chamber 36 into the second cyclone chamber44. The grill 64 can be positioned in the center of the cyclone chamber36 and includes a generally cylindrical body having a plurality of vanesor louvers 66 extending longitudinally between lower and upper ends ofthe grill 64. Openings 68 are formed between adjacent louvers 66 throughwhich air can pass. As illustrated, the louvers 68 are elongated alongthe direction of the central axis of the of the cyclone module 36. Whilenot shown, a foam or paper filter may be provided on the exterior orinterior of the grill 64.

A separator plate 70 extending radially outwardly from a lower end ofthe grill 64 and includes a downwardly depending peripheral lip 72. Theseparator plate 70 separates the first cyclone chamber 40 from the bulkdirt collection chamber 42 and can define the boundary therebetween. Afirst stage debris passage 74 from the first cyclone chamber 40 can bedefined between the separator plate 70 and the side wall 48. The firststage debris passage 74 may extend continuously around the outercircumference of the separator plate 70 and the inner circumference ofthe side wall 48.

Optionally, a helical dirt guide 76 can be provided within the firstdirt collection chamber to direct or urge debris to the bottom of thefirst dirt collection chamber and prevent re-entrainment of debris intothe first cyclone chamber 40. The helical dirt guide 76 includes a ledge78 extending from the inner wall of the module housing 38 toward thecyclone axis X, with the ledge following a generally helical trajectoryand having a free edge 80. The helical dirt guide 76 is below the debrispassage 74 and below the separator plate 70, such that no portion of thehelical dirt guide 76 is within the first cyclone chamber 40, because adirt guide 76 positioned therein could potentially disrupt or hindercyclonic separation action of dirt from the working air flow within thefirst cyclone chamber 40.

The second cyclone chamber 44 is fluidly positioned downstream of thegrill 64, and is defined by a second stage cyclone body having an uppercylindrical portion 82 and a lower frusto-conical portion 84. At leastone air inlet 86, for example a pair of opposed air inlets, is formed inthe upper cylindrical portion 82 to provide a passage for air into thesecond cyclone chamber 44. At least one second stage debris passage 88is formed in the bottom of the frusto-conical portion 84. A vortexstabilizer 90 can be provided at the bottom of the frusto-conicalportion 84, with the debris passage 88 provided just above the vortexstabilizer 90.

An upper end of the cyclone body further includes a central opening 92allowing air to pass out of the second stage and therefore defines anair outlet of the second stage. A vortex finder 94 can surround thecentral opening and extend downwardly through at least the cylindricalportion 82, and optionally partially into the frusto-conical portion 84.The vortex finder 94 can be provided as a tubular conduit that has anopen lower end.

The fines dirt collection chamber 46 is generally located underneath thecyclone body to collect dirt from the second stage debris passage 88.The fines dirt collection chamber 46 can be positioned in the center ofthe module housing 38, and aligned with the cyclone axis X. The finesdirt collection chamber 46 comprises a tubular chamber sidewall 96defining a fines collection tube having an open bottom edge 98. Thechamber sidewall 96 extends below the dirt passage 88 and optionally aportion of the chamber sidewall 96 can extend above the passage outlet88 also. The bottom edge 98 of the chamber sidewall 96 defines a debrisoutlet for the fines collection chamber 46, and is spaced from the dirtdoor 50, such that the chamber sidewall 96, and therefore the fines dirtcollection chamber 46, does not meet the dirt door 50 when the dirt door50 is closed.

The cover 52 can include a carry handle 100 that can be gripped by auser to facilitate lifting and carrying the entire vacuum cleaner 10 orjust the cyclone module 36 when removed from the vacuum cleaner 10. Thecover 52 can further include a module latch assembly 102, a pre-motorfilter assembly 104 and the outlet conduit 62 for exhausting working airfrom the cyclone module 36. The cover 52 can be pivotally mounted to themodule housing 38 by a hinge 106. A cover latch assembly 108 can beprovided opposite the hinge 106, and can be actuated by a user toselectively release the cover 52 from the closed position shown in FIG.2. The module latch assembly 102 includes a latch on the cyclone module36 and a corresponding latch receiver (not shown) provided on theupright assembly 12 of the vacuum cleaner 10 (FIG. 1), and is used toselectively coupler or release the cyclone module 36 from the primarysupport section 16.

Downstream of the second stage, the working airflow passes through thepre-motor filter assembly 104 before reaching the suction source 21. Thepre-motor filter assembly 104 includes a filter chamber 110 and a filtermedia 112 removably received within the filter chamber 110. Somenon-limiting examples of suitable filter media 112 include a non-porousor porous media, or a pleated or non-pleated media. For example, thefilter media can be a non-porous, pleated filter, such as a HEPA filter.In another example, the filter media can be a porous, non-pleatedfilter, such as a sponge-type filter.

The outlet conduit 62 can communicate with the filter chamber 110 toconduct working air that has been filtered by the filter media 112toward the suction source 21. As illustrated herein, the outlet conduit62 can extend from a wall of the filter chamber 110. It is noted thatworking air flows through the filter media 112 from a lower, upstreamend to an upper, downstream end of the media. When the cover 52 isopened by pivoting about the hinge 106, the upstream end of the filtermedia 112 will be immediately visible to the user so that a user canassess whether the filter media 112 needs cleaning or replacementwithout having to touch any component of the filter assembly 104 itself.

FIG. 4 is a perspective view of the dirt door 50 of the cyclone module36 from FIG. 2. The dirt door 50 includes a first door body 114 forclosing the bulk dirt collection chamber 42 and a platform 116 extendingabove the first door body 114 for closing the fines dirt collectionchamber 46. The platform 116 comprises an L-shaped support member 118having one end fastened to the first door body 114 and a second end thatdefines a fines empty door 120. The support 118 is attached to the firstdoor body 114 near a pivot axis Y of the dirt door 50 defined by thehinge 54 so that when the dirt door 50 is opened, the fines empty door120 swings away from the bottom edge 98 of the chamber sidewall 96together with the first door body 114 so that debris can be emptied outof the bulk and fines collection chambers 42, 46 simultaneously.

The support 118 can further comprise ribs or tines 122 that protrudelaterally towards the central axis X of the cyclone module 36. The tines122 are configured to collect and prevent re-entrainment of hair andother debris in the bulk collection chamber 42. Upon opening the dirtdoor 50, the tines 122 pivot with the dirt door 50 and become orienteddownwardly so that any debris collected thereon slides off and can bereleased into a waste container, as shown in FIG. 3. The tines 122 areelongated such that the tines 122 have a length that is substantiallygreater than their thickness, and can have a rod-like or conical shape,which tends to improve shedding and release of debris when the dirt door50 is opened.

In operation, the suction source 21, when energized, draws dirt anddirt-containing air from the suction nozzle 30 (FIG. 1) to the inletconduit 60 and into the cyclone module 36, where the dirty air swirlsaround the first cyclone chamber 40. Larger or coarser debris B fallsinto the bulk collection chamber 42. For illustration purposes, the bulkdebris B is drawn as elongated hair or threads, but that other types ofdebris may also be collected in the bulk collection chamber 42. Theworking air, which may still contain some smaller or finer debris, thenpasses through the grill 64, which can separate out some additionaldebris, and then into the second cyclone chamber 44. The working aircontinues to swirl around the inside of the second cyclone chamber 44,which causes smaller or finer debris F to separate and fall into thefines collection chamber 46. For illustration purposes, the fine debrisF is drawn as particulates, but that other types of debris may also becollected in the fines collection chamber 46. The working air, which maystill contain some even smaller or finer debris, proceeds upwardlywithin the vortex finder 94 and enters the pre-motor filer assembly 104,where additional debris may be captured by the filter media 112. Theworking air then exits the cyclone module 36 via the outlet conduit 62,and passes through the suction source 21 before being exhausted from thevacuum cleaner 10. One or more additional filter assemblies may bepositioned upstream or downstream of the suction source 21. To disposeof collected debris, the cyclone module 36 is detached from the vacuumcleaner 10 to provide a clear, unobstructed path for the debris to beemptied. Debris are emptied by opening the dirt door 50, whichsimultaneously empties the debris B, F collected in the bulk and finescollection chambers 42, 46.

FIG. 5 is a perspective sectional view of a second cyclone module 126for a vacuum cleaner. The cyclone module 126 can be used as the cyclonemodule 26 of the vacuum cleaner 10 shown in the FIG. 1, or for anothervacuum cleaner. The cyclone module 126 comprises a housing 128 at leastpartially defining a one-cyclone-stage cyclone separator including acyclone chamber 130 for separating contaminants from a dirt-containingworking airstream and an associated first or bulk collection chamber 132which receives contaminants separated by the cyclone chamber 130. Thecyclonic chamber 130 can be centered on a central axis X of the cyclonemodule 126, which can extend longitudinally through the housing 128. Itis noted that while a one-cyclone-stage cyclone separator is illustratedherein, it is also contemplated that the cyclone module 126 can beconfigured with additional cyclonic separation stages.

The module housing 128 is common to the cyclone chamber 130 and the bulkcollection chamber 132, and includes a side wall 134, a bottom wall 136,and a cover 138. The side wall 134 is illustrated herein as beinggenerally cylindrical in shape, with a diameter that increases in adirection toward the bottom wall 136. The side wall 134 includes a loweror bottom edge 139 that defines a debris outlet for the bulk collectionchamber 132. The bottom wall 136 in the illustrated example comprises adirt door that can be selectively opened, such as to empty the contentsof the bulk collection chamber 132.

The dirt door 136 is pivotally mounted to the side wall 134 by a hinge140. A door latch 142 is provided on the side wall 134, opposite thehinge 140, and can be actuated by a user to selectively release the dirtdoor 136 from engagement with the bottom edge of the side wall 134. Thedoor latch 142 is illustrated herein as comprising a latch that ispivotally mounted to the side wall 134 and spring-biased toward a closedposition shown in FIG. 5. By pressing the upper end of the door latch142 toward the side wall 134, the lower end of the door latch 142 pivotsaway from the side wall 134 and releases the dirt door 136, under theforce of gravity, to an open position, allowing accumulated dirt to beemptied from the bulk collection chamber 132 through the open bottom ofthe module housing 128, and also from a fines collection chamber asdescribed in further detail below.

With additional reference to FIG. 6, an air inlet to the cyclone module126 can be at least partially defined by an inlet conduit 144. An airoutlet from the cyclone module 126 can be at least partially defined byan outlet conduit 146 extending from the cover 138. The inlet conduit144 is in fluid communication with the suction nozzle 30 (FIG. 1) andthe outlet conduit 146 is in fluid communication with the vacuumfan/motor assembly 21 within the motor cavity 20 (FIG. 1).

The cyclone module 126 further includes an additional separator 148within the module housing 128, fluidly downstream of the cyclone chamber130. The separator 148 can be positioned in the center of the cyclonemodule 126 and includes one or more screens for filtering out debris inthe working air flow received from the first cyclonic separation stage,i.e. the cyclone chamber 130. The separator 148 illustrated comprisestwo mesh separator screens 150, 152 arranged in series and which haveprogressively smaller apertures. The first screen 150 is relativelycourse and separates out bulk debris into the bulk collection chamber132. The second screen 152 is relatively fine and filters out finedebris, which drop into a fines collection chamber 154. The finescollection chamber 154 can be emptied simultaneously with debris in thebulk collection chamber 132. With this design, separation can happen inless space, making for a smaller overall cyclone module 126. The screens150, 152 are easy to clean and are ready for use immediately aftercleaning as compared to foam filters that need to dry.

The first separator screen 150 more particularly includes a separatorbody having an upper tubular frame 156 and a lower funnel portion 158which defines the fines collection chamber 154. The tubular frame 156has an at least partially open sidewall, and openings 160 are formed inthe tubular frame 156 through which air can pass. The openings 160 arecovered by a screen or mesh material 162. The funnel portion 158 has aclosed sidewall through which air does not pass, and an open lower end164.

The second separator screen 152 can include a tubular frame 166 with aclosed lower end 168 and an at least partially open sidewall definingopenings 170 which are covered by a screen or mesh material 172. Themesh material 172 can have a finer mesh size than the mesh material 162of the first screen 150, such that finer debris are filtered out of thesecond screen 152.

A first stage debris passage 174 from the first cyclone chamber 130 canbe defined between the lower portion of the tubular frame 156 and thefunnel portion 158 and the side wall 134. The first stage debris passage174 may extend continuously around the outer circumference of the lowerportion of the tubular frame 156 and the funnel portion 158 and theinner circumference of the side wall 134. The open lower end 164 of thefirst screen 150 defines a debris outlet for the fines collectionchamber 154, which collects dirt separated out by the second screen 152.The lower end 164 is spaced from the dirt door 136, such that the funnelportion 158, and therefore the second dirt collection chamber 136, doesnot meet the dirt door 136 when the dirt door 136 is closed.

An upper end of the separator 148 further includes a central opening 176allowing air to pass out of the separator 148 and therefore defines anair outlet of the separator 148. The second screen 152 can surround thecentral opening 176 and extend downwardly therefrom.

The cover 138 can include a carry handle 178 that can be gripped by auser to facilitate lifting and carrying the entire vacuum cleaner 10 orjust the cyclone module 126 when removed from the vacuum cleaner 10. Thecover 138 can further include a module latch assembly 180, a pre-motorfilter assembly 182 and the outlet conduit 146 for exhausting workingair from the cyclone module 126. The cover 138 can be pivotally mountedto the module housing 128 by a hinge or otherwise removable to accessthe pre-motor filter assembly 182. The module latch assembly 180includes a latch on the cyclone module 126 and a corresponding latchreceiver (not shown) provided on the upright assembly 12 of the vacuumcleaner 10 (FIG. 1), and is used to selectively coupler or release thecyclone module 126 from the primary support section 16.

Downstream of the separator 148, the working airflow passes through thepre-motor filter assembly 182 before reaching the suction source 21. Thepre-motor filter assembly 182 includes a filter chamber 188 and a filtermedia 190 removably received within the filter chamber 188. Somenon-limiting examples of suitable filter media 190 include a non-porousor porous media, or a pleated or non-pleated media. For example, thefilter media can be a non-porous, pleated filter, such as a HEPA filter.In another example, the filter media can be a porous, non-pleatedfilter, such as a sponge-type filter.

The outlet conduit 146 can communicate with the filter chamber 188 toconduct working air that has been filtered by the filter media 190toward the suction source 21. As illustrated herein, the outlet conduit146 can extend from a downstream plenum 192 of the filter chamber 188.It is noted that working air flows through the filter media 190 from alower, upstream end to an upper, downstream end of the media.

The dirt door 136 includes a first door body 194 for closing the bulkcollection chamber 132 and a platform 196 extending above the first doorbody 194 for closing the fines collection chamber 154. The platform 196comprises an L-shaped support member 198 having one end fastened to thefirst door body 194 and a second end that defines a fines empty door200. The support 198 is attached to the first door body 194 near a pivotaxis Y of the dirt door 136 defined by the hinge 140 so that when thedirt door 136 is opened, the fines empty door 200 swings away from theopen lower end 164 of the funnel 158 together with the first door body194 so that debris can be emptied out of the bulk and fines collectionchambers 132, 154 simultaneously.

The support 198 can further comprise ribs or tines 202 that protrudelaterally towards the central axis X of the cyclone module 126. Thetines 202 are configured to collect and prevent re-entrainment of hairand other debris in the bulk collection chamber 132. Upon opening thedirt door 136, the tines 202 pivot with the dirt door 136 and becomeoriented downwardly so that any debris collected thereon slides off andcan be released into a waste container. The tines 202 are elongated suchthat the tines 202 have a length that is substantially greater thantheir thickness, and can have a rod-like or conical shape, which tendsto improve shedding and release of debris when the dirt door 136 isopened.

In operation, the suction source 21, when energized, draws dirt anddirt-containing air from the suction nozzle 30 (FIG. 1) to the inletconduit 144 and into the cyclone module 126, where the dirty air swirlsaround the first cyclone chamber 130. Larger or coarser debris fallsinto the bulk collection chamber 132. The working air, which may stillcontain some smaller or finer debris, then passes sequentially throughthe first screen 150, which can separate out some additional debriswhich can fall into the bulk collection chamber 132, and then throughthe second screen 152, which can separator out some additional finerdebris. The finer debris separated by the second screen 152 can fallinto the fines collection chamber 154. The working air, which may stillcontain some even smaller or finer debris, proceeds upwardly and entersthe pre-motor filer assembly 182, where additional debris may becaptured by the filter media 190. The working air then exits the cyclonemodule 126 via the outlet conduit 146, and passes through the suctionsource 21 before being exhausted from the vacuum cleaner 10. One or moreadditional filter assemblies may be positioned upstream or downstream ofthe suction source 21. To dispose of collected debris, the cyclonemodule 126 is detached from the vacuum cleaner 10 to provide a clear,unobstructed path for the debris to be emptied. Debris are emptied byopening the dirt door 136, which simultaneously empties the debriscollected in the bulk and fines collection chambers 132, 154.

FIGS. 7-8 are perspective views of a third cyclone module for a vacuumcleaner. The cyclone module 36 is substantially identical to the cyclonemodule of FIGS. 2-4, and so like elements are identified using the samereference numerals. One difference is that the fines collection tube 96is shortened within the multi cyclone design and no tines are providedon the platform 116, allowing the lower portion of the housing 38defining the first dirt collection chamber 42 to be unobstructed. Thefines collection tube 96 is closed off via the platform 116 connected tothe dirt door 50 when the dirt door 50 is closed, as shown in FIG. 7. Asthe dirt door 50 is opened to release the bulk debris, the finesplatform 116 also opens to release the collected fines debris, as shownin FIG. 8. Similarly, modified version of the cyclone module 126 shownin FIGS. 5-6 can be provided in which tines 202 are not provided on theplatform and the fines collector is shortened for an unobstructed bulkcollector.

FIG. 9 is a sectional view of a fourth cyclone module 206 for a vacuumcleaner. The cyclone module 206 can be used as the cyclone module 26 ofthe vacuum cleaner 10 shown in the FIG. 1, or for another vacuumcleaner. The cyclone module 206 comprises a housing 208 at leastpartially defining a one-cyclone-stage separator including a cyclonechamber 210 for separating contaminants from a dirt-containing workingairstream and an associated first or bulk collection chamber 212 whichreceives contaminants separated by the cyclone chamber 210. The cyclonicchamber 210 can be centered on a central axis X of the cyclone module206, which can extend longitudinally through the housing 208. It isnoted that while a one-cyclone-stage cyclone separator is illustratedherein, it is also contemplated that the cyclone module 206 can beconfigured with additional cyclonic separation stages.

The module housing 208 is common to the cyclone chamber 210 and the bulkcollection chamber 212, and includes a side wall 214, a bottom wall 216,and a top wall or cover 218. The side wall 214 is illustrated herein asbeing generally cylindrical in shape, with a diameter that increases ina direction toward the bottom wall 216. The side wall 214 includes alower or bottom edge 219 that defines a debris outlet for the bulkcollection chamber 212. The bottom wall 216 in the illustrated examplecomprises a dirt door that can be selectively opened, such as to emptythe contents of the bulk collection chamber 212.

The dirt door 216 is pivotally mounted to the side wall 214 by a hinge220. A door latch 222 is provided on the side wall 214, opposite thehinge 220, and can be actuated by a user to selectively release the dirtdoor 216 from engagement with the bottom edge of the side wall 214. Thedoor latch 222 can comprise a latch that is pivotally mounted to theside wall 214 and spring-biased toward a closed position shown in FIG.9. By pressing the upper end of the door latch 222 toward the side wall214, the lower end of the door latch 222 pivots away from the side wall214 and releases the dirt door 216, under the force of gravity, to anopen position, allowing accumulated dirt to be emptied from the bulkcollection chamber 212 through the open bottom of the module housing208.

An air inlet to the cyclone module 206 can be at least partially definedby an inlet conduit 224. An air outlet from the cyclone module 206 canbe at least partially defined by an outlet conduit 226 extending throughthe cover 218. The inlet conduit 224 is in fluid communication with thesuction nozzle 30 (FIG. 1) and the outlet conduit 226 is in fluidcommunication with the vacuum fan/motor assembly 21 within the motorcavity 20 (FIG. 1).

The cyclone module 206 further includes a secondary separator 228 withinthe module housing 208, fluidly downstream of the cyclone chamber 210.The separator 228 can be positioned in the center of the cyclone chamber210 and in the present disclosure is provided as a grill for filteringout debris in the working air flow received from the first cyclonicseparation stage, i.e. the cyclone chamber 210. The grill 228 can bepositioned in the center of the cyclone chamber 210 and includes agenerally cylindrical body having a plurality of vanes or louvers 230extending longitudinally between lower and upper ends of the grill 228.Openings 232 are formed between adjacent louvers 230 through which aircan pass. As illustrated, the louvers 230 are elongated along thedirection of the central axis of the of the cyclone module 206. An upperend of the grill 228 is open to allow air to pass out of the separator228 and into the outlet conduit 226. While not shown, a foam or paperfilter may be provided on the exterior or interior of the grill 228.Also, while the separator is shown as a grill, it is understood thatother separators may be used, such as one or more mesh screens, like thesecond example shown in FIGS. 5-6.

A separator plate 236 can extend radially outwardly from a lower end ofthe grill 228 and includes a downwardly depending peripheral lip 238.The separator plate 236 separates the cyclone chamber 210 from the bulkcollection chamber 212 and can define the boundary therebetween. Adebris passage 240 from the cyclone chamber 210 can be defined betweenthe separator plate 236 and the side wall 214. The debris passage 240may extend continuously around the outer circumference of the separatorplate 236 and the inner circumference of the side wall 214.

A fines collector tube 242 is provided beneath an open lower end of thegrill 228 and defines a fines collection chamber 244. The finescollector tube 242 includes an upper funnel portion 246 and a lower tubeportion 248 with an open lower end 250. The open lower end 250 defines adebris outlet for the fines collection chamber 244. The lower end 250 isspaced from the dirt door 216, such that the fines collector tube 242does not meet the dirt door 216 when the dirt door 216 is closed.

A fines empty door 252 is slidably mounted within the cyclone module 206to selectively close the lower open end 250 of the fines collector tube242. In one configuration, the fines empty door 252 comprises aconical-shaped door member that is slidably mounted on a guide 254 inthe fines collector tube 242. The guide 254 can be oriented coaxiallywithin the cyclone axis X. In one example, the guide 254 can comprise arod and the fines empty door 252 can be mounted to a lower end of therod. The rod can be slidably mounted within at least one bearing (notshown) such that the rod is vertically movable along the cyclone axis X.The fines empty door 252 is movable between an upward, “closed”position, shown in solid line in FIG. 9, and a downward, “open”,position shown in dotted line in FIG. 9. In the downward, “open”position, the fines empty door 252 is spaced apart from the bottom ofthe fines collector tube 242 defining a gap through which fine debrismay be emptied into the bulk collection chamber 212. In the upward,“closed” position, the fines empty door 252 seals against the open lowerend 250 of the fines collector tube 242 defining the fines collectionchamber 244.

The fines empty door 252 is actuated by vacuum pressure within thecyclone module 206. More specifically, when the cyclone module 206 isfluidly connected to the suction source 21 that generates a working airflow through the module 206, the vacuum created within the module 206lifts the fines empty door 252 into the closed position so that finedebris can be collected in the enclosed fines collection chamber 244.Conversely, when the suction source 21 is turned off or disconnectedsuch that working air flow through the module 206 stops, the fines emptydoor 252 or drops down to the open position. Fine debris collectedwithin the fines collection chamber 244 slides down the conical-shapeddoor 252 through the gap and into the bulk collection chamber 212 underthe force of gravity. The fines empty door 252 can be actuated entirelyby vacuum pressure and weight of the fines empty door 252.Alternatively, one or more springs can be mounted between the finesempty door 252 and fines collector tube 242 or another portion of thecyclone module 206 to bias the fines empty door 252 into either of the“open” or “closed” positions.

While not shown, the cyclone module 206 can further include a carryhandle that can be gripped by a user to facilitate lifting and carryingthe entire vacuum cleaner 10 or just the cyclone module 206 when removedfrom the vacuum cleaner 10, and/or a pre-motor filter assembly forfiltering the working air flow downstream of the grill 228 but beforethe air reaches the motor/fan assembly 21.

In operation, the suction source 21, when energized, draws dirt anddirt-containing air from the suction nozzle 30 (FIG. 1) to the inletconduit 224 and into the cyclone module 206, where the dirty air swirlsaround the cyclone chamber 210. Larger or coarser debris falls into thebulk collection chamber 212. The working air, which may still containsome smaller or finer debris, then passes through the grill 228, whichcan separate out some additional debris. The working air continues toswirl around the inside of the grill 228 and upper funnel portion 246,which causes smaller or finer debris to separate and fall into the finescollection chamber 244. The working air then exits the cyclone module206 via the outlet conduit 226, and passes through the suction source 21before being exhausted from the vacuum cleaner 10. One or moreadditional filter assemblies may be positioned upstream or downstream ofthe suction source 21. To dispose of collected debris, the suctionsource 21 is energized, which causes the fines empty door 252 to open inthe absence of vacuum pressure, and the fine debris to fall into thebulk collection chamber 212. The cyclone module 206 is then detachedfrom the vacuum cleaner 10 to provide a clear, unobstructed path for thedebris to be emptied. Debris are emptied by opening the dirt door 216,which empties the debris collected in the bulk and fines collectionchambers 212, 244, which now reside in the bulk collection chamber 212.

FIG. 10 is a sectional view of a fifth cyclone module 206 for a vacuumcleaner. The cyclone module 206 is substantially identical to thecyclone module 206 of FIG. 9, and so like elements are identified usingthe same reference numerals. Unlike the fourth example, the fines emptydoor 252 is not configured to automatically open and close.

The fines empty door 252 is connected to an elongate push rod 256 thatextends upwardly through the fines collector tube 242 and is accessibleby a user from the exterior of the cyclone module 206. The push rod 256includes a user-engagable first end 258 which is exterior of the cyclonehousing 208, such as above the cover 218, for access by a user from theexterior of the cyclone module 206, and a second end 260 which engagesor couples with the fines empty door 252. In this configuration, thefines empty door 252 does not automatically open and close based on thepresence or absence of vacuum pressure within the cyclone module 206.Instead, a user can manually open or close the fines empty door 252 bypushing the push rod 256 downwardly, which moves the fines empty door252 into the “open” position, shown in dotted line in FIG. 10.Conversely, to close the fines empty door 252, a user can pull the pushrod 256 upwardly to seat the fines empty door 252 in the “closed”position, shown in solid like in FIG. 10.

In operation, to empty the bulk and fines collection chambers 212, 244,a user first empties the fines collector tube 242 into the bulkcollection chamber 212 by depressing the push rod 256 and emptying thedebris into the bulk collection chamber 212. Next, a user can empty thecontents of the bulk collection chamber 212, including the contents ofthe fines collection chamber 244, by opening the hinged dirt door 216 onthe cyclone housing 208.

FIG. 11 is a sectional view of a sixth cyclone module 206 for a vacuumcleaner. The cyclone module 206 is substantially identical to thecyclone module 206 of FIG. 9, and so like elements are identified usingthe same reference numerals. Unlike the fourth example, the fines emptydoor 252 is not configured to automatically open and close, but ratheruses a push rod like the fifth example.

The fines empty door 252 and primary dirt door 216 are both connected toa push rod assembly 262 that is configured to open the fines empty door252 and primary dirt door 216 simultaneously. The push rod assembly 262comprises a primary push rod 264 and a secondary push rod 266interconnected by a support frame 268. The secondary push rod 266 isidentical to the push rod 256 of the previous example, and comprises anelongate rod extending upwardly through the fines collector tube 242 andhaving an upper end that is accessible by a user from the exterior ofthe cyclone module 206. The push rod 266 includes a user-engagable firstend 270 which is exterior of the cyclone housing 208, such as above thecover 218, for access by a user from the exterior of the cyclone module206, and a second end 272 which engages or couples with the fines emptydoor 252.

The support frame 268 extends laterally from an upper portion of thesecondary push rod 266 and is connected to an upper end of a primarypush rod 264. The primary push rod 264 extends downwardly from thesupport frame 268 to a terminal end 274, which is in register with theprimary dirt door 216 in a position opposite the door hinge 220. Theprimary push rod 264 can be mounted adjacent to the outer side wall 214of the cyclone module 206, or alternatively can be mounted adjacent tothe inner surface of the side wall 214. Likewise, the support frame 268may be exterior to or interior of the cyclone housing 208.

In operation, to empty the cyclone module 206, a user depresses thefines push rod 266 downwardly, which moves the fines empty door 252 intothe “open” position shown in dotted line in FIG. 11, whilesimultaneously moving the primary push rod 264 downwardly so theterminal end 274 pushes the primary dirt door 216 open, so that debrisfrom the bulk and fines collection chambers 212, 244 can be emptiedsimultaneously.

The cyclone module 206 can comprise one or more retaining features onthe primary dirt door 216 and on the open end of the cyclone modulehousing 208 for securing the primary dirt door 216 to the housing 208 inthe closed position. In one configuration, the retaining feature caninclude a catch or detent 276 on the primary dirt door 216 and a matingdetent or latch 278 on the cyclone module housing 208. The primary pushrod 264 can be configured to release the catch or detent 276 from themating detent or latch 278, such that the primary dirt door 216 can beopened upon depressing the push rod assembly 262. The push rod assembly262 can be spring biased so that it automatically returns to the upward“closed” position shown in solid line in FIG. 11. Alternatively, thepush rod assembly 262 can be configured without springs so that theprimary dirt door 216 pushes the push rod assembly 262 into the upward“closed” position when the primary dirt door 216 is returned to theclosed position and retained to the open bottom of the housing 208.

The above described aspects of the present disclosure provide for avariety of benefits, including improved debris collection in vacuumcleaner cyclone modules. These features, alone or in combination, createa superior-performance cyclone module. One advantage that may berealized in the practice of some aspects of the present disclosure ofthe described cyclone module is that a fines collection chamber has beenprovided which is elevated with respect to a bulk collection chamber toprovide more space for debris collection in the bulk collection chamber.

Another advantage that may be realized in the practice of some aspectsof the present disclosure of the described cyclone modules is that thebulk and fines collection chambers can be emptied simultaneously.Simultaneous emptying offers a convenient, one-step process for emptyingall the dirt collected by the module, ensuring the user that all dirthas been emptied at once. Also, a user does not have to a touch any ofthe dirty areas of the module to empty the fines collection chamber,because its emptying has been integrated with the bulk collectionchamber.

Another advantage that may be realized in the practice of some aspectsof the present disclosure of the described cyclone modules is that thedebris catching tines are provided on the emptying door of the cyclonemodule, which collect elongated or string-like debris and prevents suchdebris from wrapping around and blocking or clogging the openings of thegrill. Integrating the tines with the emptying door has the furtheradvantage of automatically cleaning debris off the tines when thecyclone module is emptied.

To the extent not already described, the different features, andstructures of the various aspects of the present disclosure of thecyclone module, may be used in combination with each other as desired,or may be used separately. That one cyclone module is illustrated hereinas having all of these features does not mean that all of these featuresmust be used in combination, but rather done so here for brevity ofdescription. Furthermore, while the cyclone module is shown as beingapplied to an upright vacuum cleaner configuration, the cyclone modulecan alternatively be applied to canister-type, stick-type, central,handheld, or portable vacuum cleaners, which share many of the samecomponents as the upright vacuum cleaner 10. Still further, while thevacuum cleaner 10 shown herein includes a vacuum collection system forcreating a partial vacuum to suck up debris (which may include dirt,dust, soil, hair, and other debris) from a surface to be cleaned andcollecting the removed debris in a space provided on the vacuum cleaner10 for later disposal, in some aspects of the present disclosure, notillustrated herein, the vacuum cleaner 10 can additionally have fluiddelivery capability, including applying liquid or steam to the surfaceto be cleaned, and/or fluid extraction capability. Thus, the variousfeatures of the different aspects of the present disclosure may be mixedand matched in various cyclone module and vacuum cleaner configurationsas desired to form new embodiments, whether or not the new embodimentsare expressly described.

While aspects of the present disclosure has been specifically describedin connection with certain specific embodiments thereof, it is to beunderstood that this is by way of illustration and not of limitation.Reasonable variation and modification are possible with the scope of theforegoing disclosure and drawings without departing from the spirit ofthe invention which, is defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

What is claimed is:
 1. A cyclone module for a vacuum cleaner, thecyclone module comprising: a module housing defining a longitudinal axisof the module; a primary separator comprising a cyclone chamber; a bulkcollection chamber having a bottom end defining a first debris outlet;at least one secondary separator fluidly downstream from the primaryseparator; a first door coupled with the module housing and closing thefirst debris outlet; a fines collection chamber having a bottom enddefining a second debris outlet wherein the bottom end of the finescollection chamber is above the bottom end of the bulk collectionchamber, with the second debris outlet spaced above the first door alongthe longitudinal axis of the module; and an L-shaped support member havea first end operably coupled to the first door and a second end defininga second door configured to close the second debris outlet.
 2. Thecyclone module of claim 1 wherein the second end of the L-shaped supportmember defines a platform spaced above the first door.
 3. The cyclonemodule of claim 1 wherein the first door is pivotally mounted to themodule housing by a hinge and the first end is adjacent the hinge. 4.The cyclone module of claim 1 wherein the L-shaped support memberfurther comprises a plurality of tines that are transverse to thelongitudinal axis of the module when the first door is closed.
 5. Thecyclone module of claim 4 wherein the tines have a length substantiallygreater than their thickness.
 6. The cyclone module of claim 4 whereinthe tines have a rod-like or conical shape.
 7. The cyclone module ofclaim 1 wherein a periphery of the first end includes a non-linearportion and a second linear portion adjoins to the second end.
 8. Thecyclone module of claim 1 wherein the module housing is common to thecyclone chamber and the bulk collection chamber, and includes a sidewall having an open lower end defining the first debris outlet, whereinthe first door is coupled with the side wall to define a bottom of themodule housing.
 9. The cyclone module of claim 8 wherein the first endof the L-shaped support member at least partially abuts the side wallsuch that the bulk collection chamber is unobstructed.
 10. The cyclonemodule of claim 1 wherein the fines collection chamber is defined by atubular wall spaced radially inwardly from the module housing.
 11. Acyclone module for a vacuum cleaner, the cyclone module comprising: amodule housing defining a longitudinal axis of the module; a primaryseparator comprising a cyclone chamber; a bulk collection chamber havinga bottom end defining a first debris outlet; at least one secondaryseparator fluidly downstream from the primary separator; a first doorcoupled with the module housing and configured to move between an openedposition and a closed position wherein the first door closes the firstdebris outlet; a fines collection chamber having a bottom end defining asecond debris outlet wherein the bottom end of the fines collectionchamber is above the bottom end of the bulk collection chamber, with thesecond debris outlet spaced above the first door along the longitudinalaxis of the module; and a support member having a first leg, defining afirst end, and a second leg, defining a second end, wherein the secondleg is at an angle from the first leg and the first end is operablycoupled to the first door and the second end defines a second door andwherein the support member is configured to move between an openedposition and a closed position where the second door closes the seconddebris outlet, wherein the first leg further comprises tines thatprotrude laterally toward a central axis of the cyclone chamber when thesecond door closes the second debris outlet; wherein movement of thefirst door to the opened position moves the second door to the openedposition.
 12. The cyclone module of claim 11 wherein the first leg is insubstantially a vertical position and the second leg is in substantiallya horizontal position when the second door closes the second debrisoutlet.
 13. The cyclone module of claim 11 wherein the first end ismounted to the first door near a pivot axis of the first door.
 14. Thecyclone module of claim 13 wherein the second leg is configured to pivotaway from the second debris outlet with movement of the first door fromthe closed position.
 15. The cyclone module of claim 11 wherein thetines have a length substantially greater than their thickness.
 16. Thecyclone module of claim 11 wherein the tines have a rod-like or conicalshape.
 17. The cyclone module of claim 11 wherein the first leg includesa non-linear portion forming the first leg at the first end and a linearportion adjoined to the second leg.
 18. The cyclone module of claim 17wherein the first leg abuts a wall defining the bulk collection chamberand the bulk collection chamber is otherwise unobstructed.
 19. A vacuumcleaner, comprising: a working air path that extends from a dirty airinlet to a clean air outlet; a suction nozzle defining the dirty airinlet of the working air path; a suction source configured to generate aworking airstream through the working air path; a cyclone module forminga portion of the working air path fluidly downstream of the suctionnozzle, and comprising: a module housing defining a longitudinal axis ofthe module; a primary separator comprising a cyclone chamber; a bulkcollection chamber having a bottom end defining a first debris outlet;at least one secondary separator fluidly downstream from the primaryseparator; a first door coupled with the module housing and configuredto move between an opened position and a closed position wherein thefirst door closes the first debris outlet; a fines collection chamberhaving a bottom end defining a second debris outlet wherein the bottomend of the fines collection chamber is above the bottom end of the bulkcollection chamber, with the second debris outlet spaced above the firstdoor along the longitudinal axis of the module; and a support memberhaving a first leg, defining a first end, and a second leg, defining asecond end, wherein the second leg is at an angle from the first leg andthe first end is operably coupled to the first door and the second enddefines a second door and wherein the support member is configured tomove between an opened position and a closed position where the seconddoor closes the second debris outlet, wherein the first leg furthercomprises tines that protrude laterally toward a central axis of thecyclone chamber when the second door closes the second debris outlet;wherein movement of the first door to the opened position moves thesecond door to the opened position.